Method for making soil conditioner

ABSTRACT

A method of making a landscaping mulch, using as its primary ingredient, spent stable bedding which has its primary ingredient ripe de bois softwood shavings. The result of the method is a mulch, particularly for landscaping applications, having a relatively high pH value, between 6.5 and 7.5, which is also useful for neutralizing the effects of acid rain.  
     The method involves the steps of mixing agricultural manure in 10 the range of 5%-25%, softwood shavings from spent stable bedding in an amount of greater than 60%, and when necessary, to augment carbon-to-nitrogen ratios, other ancillary ingredients in an amount less than 25%; producing a result by the mixing of ingredients, which has a carbon-to-nitrogen range from 100 to 200 parts of carbon to 1 part of nitrogen. Thereafter, the mixed ingredients are used to form piles, which are then over-saturated with water. Thereafter, liquid is percolated through the mixed ingredients, which liquid is expressed from the bottom of the pile by gravity. Thereafter, the pile is resaturated with the expressed liquid, now rich in tannin liquors, in order to provide a natural coloring agent for the material. Then the water flow is halted in order to allow biological activity to generate heat. Heat bakes-in the color and releases more tannins for extraction when liquid saturation is resumed. The foregoing process, beginning with resaturation, is repeated until the desired color is achieved.

FIELD OF THE INVENTION

[0001] This invention relates to methods for making soil conditioners,and more particularly to a method for coloring and converting ofsoftwoods shavings into a mulch for landscaping applications.

BACKGROUND OF THE INVENTION

[0002] In the field of producing mulch for landscaping applications; itis highly desirable-to produce a mulch with natural, dark color, andgood moisture retention properties. It is known that many commonlyproduced mulches are artificially dyed to imitate natural colors. Thedyes used for artifical coloration are known to shed water and/orinhibit water absorption. Furthermore, many of the dyes and emulsionsused to artificially color mulch are known to contain ingredients whichmay be harmful when handled,. or when leached into the soil andenvironment.

[0003] The attempt to produce mulch by artifially dying ingredients alsoincurs the use of specialty equipment, such as screeners, dryers, andthe like. The costs of such equipment ranges upwardly from $60,000 to$200,000 and above. Mulch produced with such dyes, emulsions, andequipment adds as much as $4.20 per cubic yard of finished material.

[0004] Additionally, many commercially produced mulches containundesirable ingredients, such as demolition debris, glass, plastic,creosoted wood, wood containing toxic preservatives, and some soilconditioners even contain sewage waste products.

[0005] Additionally, because of the manner in which ingredients arehandled and processed, many mulches contain weed seeds which areundesirable in a landscaping product.

[0006] A superior mulch and soil conditioner will be produced by aprocess which uses only natural, organic ingredients, has a natural,permanent dark color, has an attractive texture, has good moistureretention properties, is free of toxic materials, is free of weed seeds,is safe for humans, pets, and other living things, and qualifies in anyorganic certification program.

[0007] The present invention embodies all of the aforementioned virtuesin production and in the final product. A commonly used method forproducing mulch which most closely resembles this invention,. ZeagerU.S. Pat. No. 4,788,790, is referred to in order to illustrate thedrawbacks of that process and the improvements of this invention. Inthat patent, Zeager recommends, as an ingredient, 20% bark, preferablyoak bark. Also, Zeager states a preferred temperature of 65 degrees to85 degrees F. (18.3 degrees to 29.3 degrees C.) in order to produce thedark color for the mulch. Furthermore, Zeager finds faster processing inthe summertime, and forms piles in long and low rows with a total volumeranging between 2800 and 9400 cubic yards. As may be seen from theforegoing, the bark used by Zeager is, of course, differrent than thecombination of manure-softwood shavings recommended in the presentinvention. Also, the low temperature range used by Zeager is much toolow to include biological activity as part of the manufacturing process.The recommendation by Zeager to perform his method in summer , avoids amore efficient processing during lower ambient temperatures with thepresent invention process. Furthermore, the conical shapes recommendedin the present invention process accounts for the difference in thequantity of heat generated, 160 degrees to 200 degrees F. (70 degrees to93 degrees C.) with the present invention, as compared to 65 degrees to85 degrees F. (18.3 degrees to 29.3 degrees C.) noted by Zeager. Stillfurther, the use of a crater and concentric troughs in the pilesrecommended in the present invention process, serves to increase theuniformity of saturation of liquid within the piles and propercompaction of the piles, when compared to the Zeager process. Lastly,the present invention produces a final pH value which is “sweet”, andthis is beneficial when used with many types of landscaping plantings,whereas the same result is not achieved by Zeager.

OBJECTS AND SUMMARY OF THE INVENTION

[0008] Accordingly, a primary object of the present invention is toprovide a process for producing mulch which is safe, non-toxic,weed-free, is able to qualify in organic certification programs, andresults in mulch which is natural and darker colored for landscapingapplications.

[0009] A further object of the present invention is to provide a methodfor producing mulch which is lower in cost for equipment and ingredientsthan the methods presently available.

[0010] A further and more particular object is to provide a method forproducing mulch resulting from the use of proper moisture andtemperature levels, wherein biological activity is promoted in order tokill weed seeds and bake-in the desired color, which ranges from brownto black.

[0011] These and other objects of the invention are featured in a methodfor producing mulch which utilizes ripe de bois, softwood shavings thathave been used as a bedding in horse stables and/or cow barns. Spentbedding ingredients are mixed with approximately 10% to 20% agriculturalmanure, by volume, so that a carbon-to-nitrogen ratio ranging from 100to 200 parts carbon to 1 part nitrogen is achieved. Other ancillaryingredients can be used in the mixture, but not to exceed 25% of thevolume. Accordingly, the softwood shavings, by volume, constitute atleast 60% of the mixture. Piles are formed of the mixed ingredients toachieve maximum compression, saturation, and optimal heat generation.The shapes of the piles are made in the form of cones, with concentrictroughs and a crater truncating the top of the cone. The crater isformed so that approximately 25% of the full height of the cone isremoved, with a pre-truncation height of 34 to 47 feet. The basediameter of the cone ranges from 68 to 94 feet, and a volume range of1500 to 4000 cubic yars.

[0012] After the piles are formed in such sizes and shapes, they arethen over-saturated with water, which then percolates through the mixedingredients and is expressed from the bottom of the pile by gravity, andpooled. The expressed liquid at the base of the cone, which is now richin tannin liquors, is used to resaturate the pile and so provides thenatural coloring agent for the material. Then, water flow is halted forinherent heat to generate by biological activity in the absence of waterflow. The heat bakes-in the color and releases more tannins forextraction when liquid saturation is resumed. The process ofresaturation and halting of the water flow to generate heat bybiological activity is repeated until the desired color is achieved.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Other objects, features and advantages of the present inventionwill become apparent by reference to the following detailed descriptionof the preferred, but nonetheless illustrative, embodiment of thepresent invention, with reference to the accompaning drawing, wherein:

[0014]FIG. 1 is a representation of the pile used to place the mixedingredients, according to the invention method, so that such ingredientsmay be first over-saturated with water, and which pile has side-wallconcentric troughs and a crater at the top thereof to achieve maximumcompression, saturation and heat generation according to the presentinvention method;

[0015]FIG. 2 shows the slightly inclined grade upon which the pile isplaced, with a dammed perimeter beyond the bottom edge of the pile forexpressing and pooling the liquid resulting from the invention method;and

[0016]FIG. 3 is a block diagram representing steps of the methodaccording to the present invention.

DETAILED DESCRIPTION OF THE METHOD ACCORDING TO THE PRESENT INVENTION

[0017] According to the present invention, spent stable bedding iscollected and used to form a mixture, including, by volume, no more than5%-25% agricultural manure in relation to softwood shavings. Usually themanure will be in the range of 10% to 20%, by volume, but whenharvesting agricultural manure from high-profile show barns, manurecontent may drop below 5%. When agricultural manure content is harvestedfrom other stables the manure content can be as high as 20%-25%, but, inany case, proper mixing with the softwood shavings is essential.

[0018] Of the total volume, at least 60% should be ripe de bois softwoodshavings, or other softwood chips, plus any other ancillary ingredients,such as soiled cow bedding, grass clippings, spoiled silage or greenchop, and agricultural manure if nitrogenous supplements are called for;and straw, sawdust, or any organic woodchip or shaving of homogenoussize when carbonaceous materials are called for. This is to achieve aratio of carbon-to-nitrogen ranging from 100 to 200 parts carbon to 1part nitrogen.

[0019] The ingredients are well mixed to form that ratio, andthereafter, piles are formed to achieve maximum compression, saturation,and optimal heat generation. Such form for the pile is shown in FIG. 1,generally designated 10, wherein the total volume is shown to range from1500 to 4000 cubic yards, initially. After the conical pile is formed,crater 16 is then formed at the top of the pile 10, as shown by ghostlines. The rim of this crater should be at approximately 75% of theheight of the original pile, with the original height 14 beingapproximately 34 to 47 feet before the crater is formed. The volumerange is adhered to by forming the piles, each with a base diameter of68 to 94 feet. Depending on the exact constituent ingredients used, andtheir moisture content at the time of pile formation, the angle of theslope of the cone should optimally be 45 degrees. In forming the piles,if an elevator is used, each pile will have a more uniform shape incomparison to a pile formed by equipment such as a front-end loader orbulldozer. In either case, the proportions of the pile may vary asequipment and location dictate. However, slight variations in the shapeof the pile will not reduce the overall effectiveness of the method,according to this invention.

[0020] Additionally, concentric troughs 12, ringing the side wall of thepile at regular intervals, allow run-off spilling from the crater at thetop to more evenly saturate the pile. The number of concentric troughsmay range between three and five depending upon the volume of the pile.

[0021] For the purpose of pooling expressed liquids, such piles areformed, each on ground graded to a gradual inclination to a formedperimeter dam at the low end of the slope. The ground should be anon-porous substrate, as indicated in FIG. 2, or, if substrate uponwhich piles are formed is porous, such ground should be lined with clayor other impervious material. The pooling indicated in FIG. 2 enablesthe further use of liquid tannins formed by the pile. Additionally,liquid tannins may be stored in a tank, or series of tanks, forsubsequent use.

[0022] As will be indicated hereinafter, after forming a pile, water orpreviously saved tannin liquors are pumped onto the pile until completesaturation occurs. In other words, pumping continues beyond saturation,from the liquid that is expressed from the bottom of the pile, until theharvested amount is sufficient to resaturate the pile. It should also bestated that resaturation is best achieved by pumping the pooled tanninliquors back to the top of the pile and filling the crater.

[0023] The application of water or available tannin liquors ceases whenthe pile has become fully saturated. The moisture of the pile slowlyreduces and eventually falls through the 70% to 40% range to support.biological activity. Temperature is monitored with a probe thermometeruntil a maximum temperature of 200 degrees F. (93 degrees C.) isachieved. At this temperature, biological activity ceases, andadditionally, most weed seeds are killed off. When moisture falls below40% and/or temperature exceeds 200 degrees F. (93 degrees C.),resaturation begins.

[0024] This process of saturation and monitoring should be repeated overand over again until desired coloration is achieved from therecirculation of tannin liquors. To achieve optimum dark brown, or blackcolors, the pile is mixed and reformed at least once.

[0025] Because this is normally an outdoor activity, subject to changesin seasonal temperature and humidity, the time it takes to reach adesired temperature will vary, as will the length. of time a pileremains at a particular moisture level. Although the coloring processworks throughout the year, experience has shown it works quickest whenambient temperatures are at their lowest, so that less time will berequired to achieve desired color. When final desired color is reached,the pile should be either covered or broken down for distribution.

[0026] The final saturation of the pile yields the most potent, tanninrich liquids, and as much of this as possible should be harvested andstored to begin the saturation of a new pile.

[0027] In order to provide a more complete understanding of the presentinvention, a series of method steps, and alternatives, will now beprovided, with reference particularly to FIG. 3.

[0028] Minimally, ripe de bois, in an amount greater than 60%, andagricultural manure are mixed to produce a carbon-to-nitrogen ratio of100 to 200 parts carbon to 1 part nitrogen. The mixture is then arrangedin piles, on a substrate of graded ground, or clay lined ground, asshown in FIGS. 1 and 2. The crater at the top of the piles is filledwith water, and indeed, the piles are oversaturated with water, so thatliquid percolates through the mixed ingredients to be expressed from thebottom of the pile by gravity, and then pooled against dam 18, as shownin FIG. 2. The pooled liquid, which is rich in tannin liquors, is usedto resaturate the pile through the crater 16, in order to color themixed material. When the desired color is reached, the application ofwater and tannin liquors ceases with the pile becoming fully saturated.The moisture of the pile slowly reduces, falling through the 70% to 40%range so that biological activity is started. When the temperature of200 degrees F. (93 degrees C.) is achieved, biological activity ceases,and as moisture falls below 40%, and/or temperature exceeds 200 degrees(93 degrees C.), resaturation begins. During that process, the halt ofwater flow enables heat generated by biological activity to bake-in thecolor and release more tannins for extraction when resaturation resumes.The process is repeated until the desired color is achieved.

[0029] As an alternative, if the carbon-to-nitrogen ratio is notachieved without ancillary ingredients, such ancillary ingredients, ashereinbefore indicated, are used in an amount less than 25%, by volume,to enable the mixture to achieve the desired ratio.

[0030] The foregoing is intended to illustrate the present invention,its alternative embodiments, and the ranges of sizes and amounts asrecommended. Such is not intended to limit this invention, which is tobe accorded the scope of the following claims:

What is claimed is:
 1. A method for making a soil conditioner having ahigh pH value and a dark color without artificial dyes, comprising thesteps of: (a) mixing softwood shavings and agricultural manure toprovide, after mixing, a material having a carbon-to-nitrogen ratio inthe range of 100-200 parts of carbon to one part of nitrogen; (b)forming piles of mixed ingredients in the form of truncated cones havingcavities at the tops thereof and concentric troughs spaced on the sidewalls of each of said cones, with each cone having a volume in the rangeof 1500-4000 cubic yards; (c) over-saturating the piles with water sothat liquid percolates through the mixed ingredients to be expressedfrom the bottom of the pile by gravity and to form a pool of liquid,rich in tannin liquors proximate the base of each cone for use inresaturating said cone; (d) halting the water flow in each cone enablingthe generation of heat in the cone by means of biological activity, saidheat baking-in the color of the pile; and (e) the piles therebyreleasing more tannins for extraction as said resaturation is resumed,with the process of resaturation being repeated until desired dark coloris achieved.
 2. The method according to claim 1 wherein said mixing isaccomplished using softwood shavings in an amount by volume of at least60%.
 3. The method according to claim 2 wherein said mixing isaccomplished using agricultural manure in an amount by volume of no morethan 25%.
 4. The method according to claim 1 wherein dams are providedproximate the base of said cones for enabling the pooling of liquidexpressed from the bottom of the pile.
 5. The method according to claim3 wherein ancillary ingredients selected from the following are used forsaid mixing: soiled cow bedding, grass clippings, spoiled silage and/orgreen chop, if nitrogenous supplements are required to provide saidratio.
 6. The method according to claim 3 wherein ancillary ingredientsselected from the following are used for said mixing: straw, sawdust,and/or any organic wood chip or shaving of homogenous size, ifcarbonaceous materials are required for said ratio.